Brushless motor

ABSTRACT

A brushless motor according to the present invention is provided with: a tubular stator case; a stator core; and a rotor. The stator core includes a tubular yoke portion and a plurality of split cores. A plurality of dovetail grooves are formed in an inner peripheral surface of the yoke portion; each split core has a coil bobbin which has a mounting hole so as to penetrate in a radial direction, and a split teeth which is mounted into the mounting hole of the coil bobbin. The coil bobbin has a winding portion, and flange portions, and a clearance portion into which a winding starting end of the coil is strayed from the winding portion is formed on the inside of the one of the flange portions by reducing the thickness of the flange portion such that.

BACKGROUND OF THE INVENTION

Priority is claimed on Japanese Patent Application No. 2007-287858,filed on Nov. 5, 2007, the contents of which are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to an inner rotor type brushless motorwhich has, for example, a rotor and a stator.

DESCRIPTION OF RELATED ART

Generally, an inner rotor type brushless motor has a stator core fittedinto and fixed to a stator case and a rotor rotatably provided withrespect to the stator core, and includes permanent magnets at an outerperipheral portion thereof. This stator core includes a plurality ofteeth which project radially inward. A coil is wound around these teeth.As electric current flows into the coil, an attractive or repulsiveforce is generated between the rotor and the stator to rotate the rotor.

Among this kind of stator, there is one which includes a plurality ofteeth fixed at the internal diameter side of a cylindrical yoke portion,and a coil bobbin coupling body in which a plurality of coil bobbinsaround which a coil is wound are coupled together, and in which thiscoil bobbin coupling body is mounted on the teeth (for example, refer toJapanese Patent No. 3190511). Further, there is one in which a dovetailgroove is formed at an inner peripheral surface of a yoke portion formedin a tubular shape, and a split tooth including a projection fitted intothe dovetail groove is mounted on a coil bobbin around which a coil iswound to form a split core, and is then fitted into the dovetail groove(for example, refer to Japanese Unexamined Patent Application, FirstPublication No. 2006-296033).

Winding starting end and winding finishing end of the coil wound aroundthe coil bobbin are drawn out to the terminals, and are electricallyconnected with lead wires drawn in from the outside via the terminals.

FIG. 10 shows a conventional split core.

As shown in this drawing, a split core 118 includes a coil bobbin 160around which a coil 107 is wound, and a split tooth 161 which is mountedon the coil bobbin 160. The coil bobbin 160 is provided with terminals180 a and 180 b which electrically connect the coil 107 wound around thecoil bobbin 160 to lead wires drawn from around the outside. Further,the split tooth 161 is a member which is T-shaped in plan view, and oneend thereof is formed with a projection 167 which can fit into theaforementioned dovetail groove.

Meanwhile, in the above-mentioned brushless motor, when the coil 107 iswound around the coil bobbin 160, the coil 107 connected to a terminal180 a and the coil 107 wound around the coil bobbin 160 are differentfrom each other in directivity at the winding starting end (at theterminal 180 a in FIG. 10) of the coil bobbin 160. Therefore,overlapping coils 107 interfere with each other, and winding of the coil107 becomes difficult. This causes disordered winding of the coil 107.Thereby, the coil 107 should be mounted (refer to K′ in FIG. 10) whileavoiding the winding starting end of the coil 107. As a result, there isa problem in that the occupancy of the coil 107 in the coil bobbin 160may fall, and the magnetic flux generated from the coil 107 may becomesmall.

As described above, during mounting, a winding starting end of the coil107 should be avoided. In this respect, there is a problem in that theassembling workability of the stator core is poor.

Therefore, the present invention has been made in view of theabove-described situations, and the object of the present invention isto provide a brushless motor capable of cheaply preventing disorderedwinding of a coil to improve the occupancy of the coil, and easilyperforming the assembling operation of a stator core.

SUMMARY OF THE INVENTION

In order to solve the above problem, the brushless motor according tothe present invention is provided with: a tubular stator case; a statorcore fitted into the stator case; and a rotor rotatably supported via abearing inside the stator core, wherein: the stator core includes atubular yoke portion and a plurality of split cores which are detachablymounted on the tubular yoke portion; a plurality of dovetail grooves areformed in an inner peripheral surface of the yoke portion along an axialdirection thereof at regular intervals; each split core has a coilbobbin which is a substantially rectangular tube shape and has amounting hole so as to penetrate in a radial direction of the tubularyoke portion, and a split teeth which is mounted into the mounting holeof the coil bobbin; a projection capable of fitting into each of thedovetail grooves is formed at one end of the split teeth so as to befitted into the dovetail groove of the tubular yoke portion; the coilbobbin has a winding portion around which a coil is wound, and flangeportions which protrude outward from peripheral edges of the both endsof the coil bobbin; and a clearance portion into which a windingstarting end of the coil is strayed from the winding portion is formedon the inside of the one of the flange portions by reducing thethickness of the flange portion such that.

According to the above-described brushless motor, coils having differentdirectivity are prevented from overlapping and interfering with eachother by allowing the coil drawn from around a winding starting end ofthe coil escape to the clearance, and disordered winding of the coilsdoes not occur. Further, since it is unnecessary to avoid coils havingdifferent directivity, assembling workability improves, the coil bobbinitself is not enlarged, an apparatus is miniaturized, and the occupancyof the coil can be cheaply improved.

It may be arranged such that a flange portion of the coil bobbin has anenlarged portion which protrudes outward from the surface of the flangeportion; and a clearance groove is formed on the enlarge portion alongthe axial direction of the stator core.

In this case, in addition to the above effects, the projection of thesplit tooth projects in plan view when the split tooth is mounted on thecoil bobbin because the clearance groove is formed in the coil bobbin.Therefore, when the projection of the split tooth is made to fit to thedovetail groove of the main core, the split tooth can be directlypressed through the clearance groove. Accordingly, compared with a casewhere the split core is pressed over the coil bobbin unlike the relatedart, the split core can be made to fit into the dovetail core withoutdamaging the coil bobbin.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially sectional view of a brushless motor of anembodiment of the invention.

FIG. 2 is a plan view of a stator core.

FIG. 3 is a plan view showing a stator case from the rear side.

FIG. 4 is a plan view showing the stator case from the front side.

FIG. 5 is a partially sectional view taken along a line B-B′ of FIG. 4.

FIG. 6 is an exploded perspective view of the stator core.

FIG. 7A is a left side view of a coil bobbin.

FIG. 7B is a plan view of a coil bobbin.

FIG. 8 is a plan view of a split core.

FIG. 9 is an exploded perspective view of a brushless motor.

FIG. 10 is a plan view of a conventional split core.

DETAILED DESCRIPTION OF THE INVENTION

Next, an embodiment of the invention will be described with reference tothe drawings. In the following description, the right side of FIG. 1 isdefined as the other end side (front side), and the left side of FIG. 1is defined as one end side (rear side).

FIG. 1 is a partially sectional view taken along a line A-A′ of FIG. 4.As shown in FIG. 1, a brushless motor 1 of this embodiment is an innerrotor type brushless motor 1, and includes a cylindrical stator 2, and arotor 3 rotatably provided inside the stator 2.

As shown in FIGS. 2 to 6, the stator 2 includes a cylindrical statorcase 2 a, and a stator core 2 b fitted into and fixed to the stator case2 a.

The stator core 2 b is formed by laminating a magnetic sheet materialaxially or pressing magnetic metal powder, and includes a tubular yokeportion 11. At an inner peripheral surface of the yoke portion 11, sixcommutating-pole teeth 12 which extend radially inward are integrallyformed at equal intervals in the peripheral direction of the yokeportion 11.

A root portion 13 of each of the commutating-pole teeth 12 is graduallyenlarged to the yoke portion 11, and is formed in the shape of a fan,and each side face of the root portion 13 includes an inclined shoulder14. The shoulders 14 of adjacent commutating-pole teeth 12 which faceeach other are formed so as to be parallel to each other, and asubstantially rectangular slot 15 is formed between the adjacentcommutating-pole teeth 12.

By forming the shoulders 14 of the adjacent commutating-pole teeth 12which face each other so as to be parallel to each other in this way,the space of the slot 15 can be more largely secured. Also, three setbolt holes 16 are formed at regular intervals in the peripheraldirection along the axial direction of the stator core 2 b in the rootportions 13 of the commutating-pole teeth 12.

Dovetail grooves 17 are formed along the axial direction of the yokeportion 11 at the inner peripheral surface of the yoke portion 11. Eachof the dovetail grooves 17 is formed in an intermediate position of theadjacent commutating-pole teeth 12, and is formed so as to be open intothe slot 15. A main core 24 is constituted by the yoke portion 11 andthe commutating-pole teeth 12.

A split core 18 around which a coil 7 is wound is provided between theadjacent commutating-pole teeth 12. Six split cores 18 are provided atregular intervals in the peripheral direction of the yoke portion 11,and are arranged alternately with the commutating-pole teeth 12. Inorder to make the description more easily understood in FIG. 2, a coilbobbin 60 to be described later is omitted.

As shown in FIG. 1, an opening at one end side of (rear side) of thestator case 2 a is formed with a stepped portion 20 a whose externaldiameter is reduced toward an outer peripheral edge, and a rear bracket5 is provided so as to close an opening at the rear side. The rearbracket 5 is formed in the shape of a tube with a bottom formed of, forexample, aluminum having a high heat transfer rate, and is constitutedby a peripheral wall 50 and an end portion (end face) 51.

A stepped portion 52 corresponding to the stepped portion 20 a of thestator case 2 a is formed at the inner peripheral edge of the peripheralwall 50 of the rear bracket 5, and the stepped portion 52 is fitted ontoand fixed to the stepped portion 20 a of the stator case 2 a. The axialcenter of the end portion 51 is formed with an insertion hole 53 forallowing one end of the rotor 3 to be inserted therethrough.

In the rotor 3, a substantially cylindrical magnet 3 b is fitted ontoand fixed to a shaft 3 a having stepped portions 19 and 21 at both endsthereof. The magnet 3 b is magnetized such that its pole may alternatelychange in the peripheral direction.

A bearing housing 54 is formed axially inside the insertion hole 53, anda bearing 10 which rotatably supports the shaft 3 a is press-fitted intothe bearing housing. The bearing 10 is press-fitted such that an endface at an outer ring 10 a thereof is butted against the end portion 51of the rear bracket 5, and is press-fitted such that an end face at aninner ring 10 i thereof is butted against the stepped portion 19 at oneend of the shaft 3 a.

A substantially disc-like substrate 8 is provided at the outerperipheral side of the bearing housing 54. The substrate 8 suppliesexternal power to the coil 7, is electrically connected with an externalpower source which is not shown via a plurality of lead wires 32, and awinding starting end and a winding finishing end of the coil 7 woundaround the split core 18 are electrically connected via terminals 80 ofthe split core 18 to be described later. The lead wires 32 are drawn outalong the axial direction, and are connected to an external power sourcevia a draw-out hole (not shown) which is formed in a lower portion ofthe rear bracket 5. A fixing plate 35 is provided in the drawn-out leadwires 32 via a grommet 38, and is fastened and fixed by a pair of bolts36 and 36. Reference numeral 32 a in FIG. 1 is a coated tube whichbundles and covers the lead wires 32.

Three set bolt holes 25 (to be described later) through which set bolts48 are inserted are formed at regular intervals along the peripheraldirection axially inside the rear bracket 5. Meanwhile, a cover 30 isfastened and fixed to the axial outside of the rear bracket 5 with bolts31. The cover 30 closes the end of the rotor 3 at the rear bracket 5,and an optical encoder fixed to this end. The optical encoder detectsthe rotation angle of the rotor 3. A rotor position detecting method ofthe brushless motor 1 in this embodiment is not limited to the opticalencoder, but may be carried out by a magnetic encoder, a resolver, ahall IC, and a sensor magnet, and may be carried out by sensor-lessdriving.

Meanwhile, as shown in FIGS. 4 and 5, in the opening at the other endside (front side) of the stator case 2 a, a stepped portion 20 b whoseexternal diameter is reduced toward the outer peripheral side similarlyto one end side is formed and an inner flange portion 22 overhungaxially inward from the stepped portion 20 b between the split cores 18is formed. The inner flange portion 22 is formed so as to overlap theyoke portion 11 and the root portions 13 of the commutating-pole teeth12, which are described above, and the reverse side thereof abuts on thestator core 2 b. Further, set bolt holes 23 are formed in the innerflange portion 22 in correspondence with the set bolt holes 16 of theabove-described stator core 2 b.

A bearing 9 which rotatably supports the shaft 3 a is provided at theother end side of the shaft 3 a. The bearing 9 is press-fitted such thatan end face at an inner ring 9 i thereof is butted against the steppedportion 21 at the other end of the shaft 3 a.

A front bracket 4 is provided at the other end side of the stator case 2a so as to close an opening at the front side. The front bracket 4 isformed in the shape of a tube with a bottom formed of, for example,aluminum having a high heat transfer rate, and is constituted by aperipheral wall 43 and a bottom plate 44.

The peripheral wall 43 of a front bracket 4 is thickly formed, and itsend face is formed as a face 45 which butts against the inner flangeportion 22 of the stator case 2 a. Here, the butting face 45 is formedin the same shape as the width of the inner flange portion 22. A steppedportion 41 corresponding to the stepped portion 20 b is formed at theouter peripheral side of the peripheral wall 43. As the stepped portion41 is fitted onto the stepped portion 20 b of the stator case 2 a, thefront bracket 4 is fixed such that the butting face 45 and the innerflange portion 22 are fixed so as to abut each other face to face.

A boss 40 is formed axially outward at the axial center of the frontbracket 4. An insertion hole 42 for allowing the other end side of theshaft 3 a to be inserted therethrough is formed at the axial center ofthe boss 40, and the axial inside of the insertion hole 42 is formed asa bearing housing 47 in which a wave washer 46 is received. Also, theother end side of the shaft 3 a is inserted through the insertion hole42 such that the bearing 9 press-fitted into the shaft 3 a is receivedin the bearing housing 47 via the wave washer 46. The wave washer 46presses an outer ring 9 a of the bearing 9 to give a force in a thrustdirection to the inner ring 9 i via balls. Three stepped portions 37(refer to FIGS. 1 and 9) which are cut out at the axial direction atregular intervals in the peripheral direction are formed at a peripheraledge of the front bracket 4, and set bolt holes 39 are formed incorrespondence with the above-described set bolt holes 16 and 23.

As shown in FIG. 1, the front bracket 4 and the stator 2, and the rearbracket 5 are connected by inserting and fastening the set bolts 48 fromthe set bolt holes 39. Heads of the set bolts 48 are received in thestepped portions 37, and thereby become flush with the bottom plate 44of the front bracket 4.

As shown in FIGS. 6 to 8, the above-described split core 18 includes thecoil bobbin 60 around which the coil 7 is wound, and a split tooth 61which is mounted on the coil bobbin 60. The split tooth 61 is a memberwhich is T-shaped in plan view, and one end thereof is formed with aprojection 67 which can fit into the dovetail groove 17 of the main core24.

The coil bobbin 60 is made of a material having an insulating property,such as resin, and includes a rectangular tubular winding portion 62(refer to FIG. 7) around which the coil 7 is wound. A central portion ofthe coil bobbin 60 is formed with a rectangular mounting hole 63 whichpasses through of the coil bobbin 60 in its width direction (the radialdirection of the stator core 2 b), and this central portion is mountedwith the split tooth 61 (refer to FIG. 6).

Upper and lower ends of the winding portion 62 include an upper flangeportion 64 and a lower flange portion 65 which extend outward from theperipheral edge thereof. One end side of the upper flange portion 64 ofthe coil bobbin 60 is formed as an enlarged portion 66, and the tip ofthe upper flange portion is provided with two terminals 80. One of theterminals 80 is a terminal 80 a of a winding starting end of the coil 7,and the other of the terminals 80 is a terminal 80 b of a windingfinishing end of the coil 7, and the coil 7 wound around the coil bobbin60 is connected to the terminals.

Here, a clearance groove 68 which is semicircular in plan view is formedin the enlarged portion 66 of the coil bobbin 60 along the longitudinaldirection of the coil bobbin 60. The clearance groove 68 is formed withalmost the same width as the mounting hole 63 of the coil bobbin 60between two terminals 80. That is, after the split tooth 61 is insertedthrough the mounting hole 63 of the coil bobbin 60, at least theprojection 67 of the split tooth 61 is adapted to be capable of beingvisually seen over the enlarged portion 66 (refer to FIG. 8) in planview.

An inclined portion 69 is formed at the terminal 80 a of the windingstarting end in a reverse face of the upper flange portion 64 of thecoil bobbin 60. The inclined portion 69 is formed in the shape having aslope to a halfway portion of the upper flange portion 64 along thelongitudinal direction from the tip of the enlarged portion 66.Specifically, the inclined portion is preferably inclined as much as thethickness of one turn of the coil 7.

Here, a method of assembling the brushless motor 1 of this embodimentwill be described.

First, as shown in FIG. 8, the coil 7 is wound around the coil bobbin60. Specifically, the coil 7 is connected to the terminal 80 a of thewinding starting end, and is wound around the winding portion 62. Here,the coil 7 drawn from around the terminal 80 a is different from thecoil 7 wound around the winding portion 62 in directivity (refer to K inFIG. 8). However, by allowing one turn of the coil 7 drawn from aroundthe terminal 80 a to escape to the inclined portion 69, overlappingcoils 7 can be easily loaded without interfering with each other.

Next, as shown in FIGS. 6 and 9, the mounting hole 63 of the coil bobbin60 is mounted with the split tooth 61, and the projection 67 of thesplit tooth 61 and the dovetail groove 17 of the main core 24 are madeto fit to each other. Then, when the split core 18 is pushed into thedovetail groove 17, the stator core 2 b is assembled by pressing theprojection 67 of the split tooth 61 by a pin through the clearancegroove 68 formed in the coil bobbin 60. The stator core 2 b is fittedinto and fixed to the stator case 2 a.

Next, the terminals 80 and the lead wires 32 are connected via thesubstrate 8 at one end side (rear side) of the stator case 2 a, and therear bracket 5 is closed by the press-fitted bearing 10. Then, after thelead wires 32 are drawn out of the draw-out hole of the rear bracket 5,the fixing plate 35 is fastened and fixed via the grommet 38 by thebolts 36.

Meanwhile, the bearing 9 is press-fitted from the other end side of theshaft 3 a of the rotor 3 in which the magnet 3 b has been magnetized inadvance. At this time, the bearing 9 is press-fitted such that itsportion at the inner ring 9 i is butted against the stepped portion 21of the shaft 3 a. Then, the rotor 3 is inserted from the other end side(front side) of the stator case 2 a, and is press-fitted until thestepped portion 19 of the shaft 3 a is butted against the inner ring 10i of the bearing 10 press-fitted into the bearing housing 54 of the rearbracket 5.

Next, the opening at the other end of the stator case 2 a is closed bythe front bracket 4. At this time, the bearing 9 is set in a state wherethe wave washer 46 is received in the bearing housing 47, and the outerring 9 a of the bearing 9 is pressed by the wave washer 46. Along withthis, the inner flange portion 22 of the stator case 2 a is made to abuton the butting face 45 (refer to FIG. 5) of the front bracket 4 face toface.

Then, the front bracket 4 and the stator 2, and the rear bracket 5 areconnected by inserting and fastening the set bolts 48 through the setbolt holes 16, 23, 25, and 39.

Here, if the fastening operation is completed by the set bolts 48, theinside of the brushless motor 1 is pressurized. Specifically, the wavewasher 46 is made to abut on the outer ring 9 a of the bearing 9.Thereby, the pressure of the wave washer is transmitted to the innerring 9 i of the bearing 9 via the balls, eliminating rattling caused byan inner clearance between the inner and outer rings 9 i and 9 a, and istransmitted from the inner ring 9 i of the bearing 9 toward the innerring 10 i of the bearing 10 via the shaft 3 a of the rotor 3,eliminating rattling caused by an internal clearance between the innerand outer rings 10 i and 10 a of the bearing 10. Then, since all theinner and outer rings 9 i, 9 a, 10 i, and 10 a of the bearings 9 and 10are press-fitted and fixed, it is not necessary to fix the bearings withset screws, etc., it is possible to reduce the number of parts, andmoreover, and it is possible to set the internal clearance of each ofthe bearings 9 and 10 to zero. Moreover, it is possible to make thebrushless motor 1 small and lightweight, and it is possible to suppressthe vibration or noise during the operation of the brushless motor 1.

Accordingly, according to the above-described embodiment, coils 7 havingdifferent directivity are prevented from overlapping and interferingwith each other by allowing a winding starting end of the coil 7 drawnfrom around the terminal 80 a of a winding starting end to escape to theinclined portion 69 formed in the coil bobbin 60. That is, the coilbobbin 60 itself is not made large, and disordered winding of the coil 7can be prevented by easy working of only inclining the upper flangeportion 64 of the coil bobbin 60 in the shape having a slope. Therefore,it is possible to make the brushless motor 1 to be small, and it is alsopossible to improve the occupancy of a coil 7 inexpensively. Also, sincethere is no disordered winding during the winding operation of the coil7, an assembling operation can be performed easily.

Since the enlarged portion 66 of the coil bobbin 60 is formed with theclearance groove 68, when the coil bobbin 60 has been mounted on thesplit tooth 61, the projection 67 of the split tooth 61 projects in planview. Therefore, when the projection 67 of split tooth 61 is made to fitto the dovetail groove 17 of the main core 24, the split tooth 161(refer to FIG. 10) is not pressed over the coil bobbin 160 (refer toFIG. 10) unlike the related art, and the split tooth 61 can be directlypressed through the clearance groove 68. Accordingly, compared with acase where the split core 18 is pressed over the coil bobbin 60 made ofresin, etc., the split core 18 can be made to fit to the main core 24without damaging the coil bobbin 60.

The root portion 13 of each of the commutating-pole teeth 12 in the maincore 24 spreads in the shape of a fan, and includes the inclinedshoulder 14. Therefore, the wall thickness of the yoke portion 11 can bemade small while a magnetic path width corresponding to a magnetic fluxgenerated from the coil 7 can be sufficiently secured and the space forforming the set bolt holes 23 of the set bolts 48 can be secured.

That is, the space of the slot 15 formed between the adjacentcommutating-pole teeth 12 can be largely secured by making the wallthickness of the yoke portion 11 small. Therefore, the cross-sectionalarea of the coil 7 can be increased without enlarging the brushlessmotor 1 itself or without complicating the winding of the coil 7.

For example, the high output of the brushless motor 1 can be achieved,and even in a case where the set bolts 48 with a large diameter are usedwhen the brushless motor 1 with a long axial length is manufactured, thespace for forming the set bolt holes 16 can be sufficiently secured inthe root portions 13 of the main core 24. Therefore, it is possible tomanufacture a high-output brushless motor 1 without enlarging thebrushless motor 1 in the radial direction.

The inner flange portion 22 which extends radially inward is formed inthe opening at the other end of the stator case 2 a, the peripheral wall43 of the front bracket 4 is thickly formed as the butting face 45, andthe stator case 2 a and the front bracket 4 are made to abut each otherat the inner flange portion 22 and the butting face 45. This can improvethe contact area between the stator case 2 a and the front bracket 4.Also, since this can reduce the thermal resistance between the statorcase 2 a and the front bracket 4, the heat generated by the coil 7 canbe efficiently dissipated through the stator case 2 a and the frontbracket 4 from the stator core 2 b.

Accordingly, since the temperature rise of the coil 7 can be suppressed,the number of turns of the coil 7 can be increased, and the rated torquecan be improved. Further, since the contact area between the stator case2 a and the front bracket 4 improves, the positioning of the stator core2 b at the time of assembling becomes easy, thereby it is possible toimprove working efficiency.

It should be understood that the invention is not limited to theabove-described embodiment, but various modifications may be made to theabove-described embodiment without departing from the spirit of theinvention.

For example, in this embodiment, a coil clearance portion is inclined inthe shape having a slope. However, the coil clearance portion may beformed in the shape of a groove as long as it has the structure in whicha winding starting end of a coil is escaped. Further, the shape of theclearance groove is formed in the shape of a semicircle. However, theclearance groove can be suitably changed in design if it has thestructure in which the split tooth is directly pushed in. The set boltholes may be formed in the shape of a U-shaped groove.

Further, bolt holes for attaching a brushless motor between the set boltholes may be formed at the root portions of the commutating-pole teeth.

While preferred embodiments of the invention have been described andillustrated above it should be understood that these are exemplary ofthe invention and are not to be considered as limiting. Additions,omissions and substitutions, and other modifications can be made withoutdeparting from the spirit or scope of the present invention.Accordingly, the invention is not to be considered as being limited bythe foregoing description, and is only limited by the scope of theappended claims.

1. A brushless motor comprising: a tubular stator case; a stator corefitted into the stator case; and a rotor rotatably supported via abearing inside the stator core, wherein: the stator core includes atubular yoke portion and a plurality of split cores which are detachablymounted on the tubular yoke portion; a plurality of dovetail grooves areformed in an inner peripheral surface of the yoke portion along an axialdirection thereof at regular intervals; each split core has a coilbobbin which is a substantially rectangular tube shape and has amounting hole so as to penetrate in a radial direction of the tubularyoke portion, and a split teeth which is mounted into the mounting holeof the coil bobbin; a projection capable of fitting into each of thedovetail grooves is formed at one end of the split teeth so as to befitted into the dovetail groove of the tubular yoke portion; the coilbobbin has a winding portion around which a coil is wound, and flangeportions which protrude outward from peripheral edges of the both endsof the coil bobbin; and a clearance portion into which a windingstarting end of the coil is strayed from the winding portion is formedon the inside of the one of the flange portions by reducing thethickness of the flange portion.
 2. The brushless motor according toclaim 1, wherein: a flange portion of the coil bobbin has an enlargedportion which protrudes outward from the surface of the flange portion;and a clearance groove is formed on the enlarge portion along the axialdirection of the stator core.
 3. A brushless motor comprising: a tubularstator case; a stator core fitted into the stator case; and a rotorrotatably supported via a bearing inside the stator core, wherein: thestator core includes a tubular yoke portion and a plurality of splitcores which are detachably mounted on the tubular yoke portion; aplurality of dovetail grooves are formed in an inner peripheral surfaceof the yoke portion along an axial direction thereof at regularintervals; each split core has a coil bobbin which is a substantiallyrectangular tube shape and has a mounting hole so as to penetrate in aradial direction of the tubular yoke portion, and a split teeth which ismounted into the mounting hole of the coil bobbin; a projection capableof fitting into each of the dovetail grooves is formed at one end of thesplit teeth so as to be fitted into the dovetail groove of the tubularyoke portion; the coil bobbin has a winding portion around which a coilis wound, and flange portions which protrude outward from peripheraledges of the both ends of the coil bobbin; a flange portion of the coilbobbin has an enlarged portion which protrudes outward from the surfaceof the flange portion; and a clearance groove is formed on the enlargeportion along the axial direction of the stator core.